Polyaxial screw assembly

ABSTRACT

A polyaxial screw assembly includes a pedicle screw, a coupling, an insert, and a housing. The pedicle screw includes a shank having a helical thread formed thereon and a head at one end. The coupling is positioned on top the pedicle screw and releasably engages portions of the head. The coupling and pedicle screw are positioned within a distal portion of the housing. The pedicle screw is slid through an opening in the insert and the insert is thread into the distal portion of the housing to retain the coupling and the pedicle screw within the housing. The pedicle screw is rotatable and pivotable relative to the housing. Compressing the coupling within the housing locks the pedicle screw in a desired orientation.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to, and the benefit of, U.S.Provisional Patent Application Ser. No. 61/000,072, filed on Oct. 23,2007, the entire contents of which are hereby incorporated by reference.

BACKGROUND

1. Technical Field

The present disclosure relates to pedicle screws and, more particularly,to a polyaxial screw assembly.

2. Background of Related Art

The adult human spinal column has more than twenty discrete bonessequentially coupled to one another by a tri joint complex consisting ofan anterior disc and the two posterior facet joints. The anterior discsof adjacent bones are cushioned by cartilage spacers referred to asintervertebral discs. The bones of the spinal column are anatomicallycategorized as being members of one of four classifications: cervical,thoracic, lumbar, or sacral. The cervical portion of the spine is thetop of the spine and includes the first seven vertebrae from the base ofthe skull. The next twelve bones are the thoracic vertebrae. Thereafter,the next five bones form the lumbar vertebrae. Connecting to the lumbar,the sacral bones are at the base of the spine and include the coccyx.

The spine is a highly flexible structure, capable of a high degree ofcurvature and twist in nearly every direction. Genetic or developmentalirregularities, trauma, chronic stress, tumors, and disease, however,can result in spinal pathologies. Spinal pathologies either limit therange of motion of the spine or threaten the critical elements of thenervous system housed within the spinal column. There are many systemsthat immobilize the spine by implanting artificial assemblies in or onthe spinal column. The implantable assemblies are classified asanterior, posterior, or lateral implants. As the name of theclassification suggests, lateral and anterior implants are coupled tothe anterior portion of the spine. Posterior implants generally compriserod assemblies that are attached to the spinal column by either 1) hookscoupled to the lamina or the transverse processes, or 2) by screwsinserted through the pedicles.

The screws are implanted through the posterior lateral surfaces of thelaminae, through the pedicles, and into their respective vertebralbodies. The screws have upper portions that are coupling elements forreceiving and securing an elongate rod. The elongate rod extends alongthe axis of the spine and is coupled to the screws via the couplingelements. The rigidity of the elongated rod aligns the spine in a moredesired shape.

Inserting screws along a misaligned curvature of the spine, whileexactly positioning the coupling elements, can be difficult. Thecoupling elements must be placed in a way that a rod can be passedtherethrough without damaging the screws. As a result, the surgeon mustbe careful when trying to properly align fixed screws, which increasesthe operating time and leads to an increased probability of acomplication.

The art contains screws that permit a limited amount of freedom withrespect to angulation of the coupling element. These assemblies,however, are generally complex, unreliable, and lack durability.

SUMMARY

A polyaxial screw assembly is presently disclosed. The polyaxial screwassembly includes a pedicle screw, a coupling, a housing, and an insert.The pedicle screw has a head having a recess and a plurality of gaps.The coupling has a plurality of knobs that mate with the plurality ofgaps and the lower surface of the coupling mates with the recess in thehead of the pedicle screw. The housing has a passageway that forms alongitudinal axis through the housing. The passageway narrows at a pointbetween a distal opening and a proximal opening. The distal portion ofthe passageway is partially threaded. The insert is configured to beslid over the shank of the pedicle screw and thread into the distalopening of the housing. The insert has a threaded outer diameter thatmates with the threaded distal portion of the housing and an openingextending therethrough. The diameter of the opening of the insert isdimensioned to be less than the outer diameter of the head and greaterthan the shank of the pedicle screw. As a result, the insert sandwichesthe pedicle screw and coupling within the housing.

Threading the insert into the bottom of the housing joins the pediclescrew and coupling arrangement to the housing, thereby forming thepolyaxial screw assembly. As assembled, the pedicle screw is rotatableand pivotable in the housing.

A proximal portion of the housing is shaped to form a U-shaped saddle.Placing a rod member in the saddle of the housing acts to compress thehead of the pedicle screw against an inner surface of the housing,thereby securing the pedicle screw in a desired orientation. A lockingmember or setscrew is then threaded into the top of the housing forsecuring the rod member in position with respect to the housing. Eachpart of the polyaxial screw assembly is made of a biocompatiblematerial.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the presently disclosed polyaxial screw assembly aredescribed herein with reference to the accompanying drawings, wherein:

FIG. 1A is a perspective view of a polyaxial screw assembly according tothe present disclosure;

FIG. 1B is an exploded front view, with parts separated, of thepolyaxial screw assembly of FIG. 1A;

FIG. 2 is a front view of a housing;

FIG. 2A is a side cross-sectional view, taken along section line A-A, ofthe housing of FIG. 2;

FIG. 3 is a bottom perspective view of an insert;

FIG. 4 is a perspective view of a coupling;

FIG. 5 is a perspective view of a pedicle screw;

FIG. 6 is an exploded front view, with parts separated, of a polyaxialscrew assembly in accordance with another embodiment of the presentdisclosure;

FIG. 7 is an exploded front view, with parts separated, of a polyaxialscrew assembly in accordance with still another embodiment of thepresent disclosure; and

FIG. 8 is a perspective view of the coupling, the pedicle screw, andthree connectors in accordance with the embodiment of FIG. 7.

Other features and advantages of the present disclosure will becomeapparent from the following detailed description, taken in conjunctionwith the accompanying drawings, which illustrate, by way of example, theprinciples of the present disclosure.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Embodiments of the presently disclosed polyaxial screw assembly will nowbe described in detail with reference to the drawing figures whereinlike reference numerals identify similar or identical elements. In thedrawings and in the description which follows, the term “proximal”, asis traditional, will refer to the end of the polyaxial screw assemblywhich is closest to the operator while the term “distal” will refer tothe end of the polyaxial screw assembly which is furthest from theoperator.

Referring initially to FIGS. 1A and 1B, in which like reference numeralsidentify similar or identical elements, a polyaxial screw assembly isgenerally designated as 100. The polyaxial screw assembly 100 includes apedicle screw 10, a coupling 30, an insert 50, and a housing 70. Thesteps of assembling the polyaxial screw assembly 100 include positioningthe coupling 30 on top of the pedicle screw 10 and then the housing 70is positioned over the coupling 30 and the pedicle screw. Then theinsert 50 is passed over the distal end of the pedicle screw 10 andalong the shaft towards the bottom of the housing 70. The insert 50 isthen screwed into the housing 70 to hold the polyaxial screw assembly100 together. The specific arrangements and interconnections of thevarious components will be described in further detail hereinafter.

Turning now to FIGS. 2 and 2A, the housing 70 will be described inadditional detail. The housing 70 includes an annular body portion 72having an opening therethrough with a pair of upstanding fingers 74. AU-shaped saddle 76 is defined between the fingers 74 and is configuredfor receiving a rod member (not shown). The body portion includes agenerally helical thread 73 that is located in a lower section of thebody portion 72 and is adapted for threadably engaging a correspondingthread 56 of the insert 50, as will be described in detail hereinafter.Each of the fingers 74 includes a portion of a generally helical thread75 formed on the inner surface of the housing. The thread 75 isconfigured for threadably engaging a corresponding thread on a lockingelement (not shown). The locking element may be a setscrew or anotherthreaded component, as is known in the art. The opening at the bottom ofthe housing 70 is capable of receiving the coupling 30 and the pediclescrew 10 without being able to completely pass therethrough.

As seen in FIG. 4, the coupling 30 has a generally annular body 32 witha plurality of outwardly extending knobs 36. In the illustratedembodiment, four knobs 36 are shown and each knob 36 is offset 90° fromthe adjacent knobs 36. It is envisioned that the knobs extend from thescrew head and the annular body of the coupling has recesses to acceptthe knobs. An annular flange 34 is disposed at one end of the coupling30. The flange 34 has an outer diameter that is greater than the outerdiameter of the body 32. Additionally, a recess 38 is formed in the body32 of the coupling 30. The recess 38 is configured and adapted forreleasable engagement with a driving tool (not shown), as is known inthe art. Although the recess 38 is illustrated with a six-pointed starpattern, other suitable configurations are contemplated. A tapered outersurface 33 is located about the distal end of the coupling 30.

Turning now to FIG. 5, the pedicle screw 10 will be discussed in detail.The pedicle screw 10 includes a shank 16 having a helical thread 14formed thereon. A cutting portion 12 is formed at a distal end of thepedicle screw 10. A head 18 is located at a proximal end of the pediclescrew 10 and includes a plurality of segments 18 a. The segments 18 aare arranged in a circular configuration about the head 18. A gap 17exists between each of the segments 18 a and is adapted for releasablyreceiving the plurality of knobs 36 of the coupling 30 (FIG. 4). Arecess 20 is defined between the segments 18 a in the center of the head18. The recess 20 has a tapered inner surface for receiving the body 32of the coupling 30 (FIG. 4). When the coupling 30 is located in therecess 20, each of the knobs 36 are positioned within one of thecorresponding gaps 17. Thus, the coupling 30 and the pedicle screw 10are rotatably coupled such that rotation of the coupling 30 causes acorresponding rotation of the pedicle screw 10.

As seen in FIG. 3, the insert 50 is an annular ring 52 having an opening54 extending therethrough. The opening 54 has a diameter that is greaterthan the shank 16 of the pedicle screw 10 and is smaller than the head18 of the pedicle screw 10. A generally helical thread 56 is located onthe outer surface of the annular ring 52. The thread 56 mates with thethread 75 of the housing 70 (see FIG. 2A).

Referring to FIGS. 1A-5, assembly and usage of the polyaxial screwassembly 100 will now be discussed in detail. Initially, the coupling 30is seated within the top of the pedicle screw 10, such that each of theknobs 36 is interlocked with a corresponding gap 17 and the outerdiameter of the coupling body 32 pivotably mates with the inner diameterof the pedicle screw recess 20. As a result, the coupling 30 is slidablyreceived in the recess 20. The tapered outer surface 33 mates with thetapered inner surface of the recess 20 and allows the coupling 30 to beseated within the recess 20.

As previously discussed, when the coupling 30 is seated in the recess 20of the pedicle screw 10, rotation of the coupling 30 causes acorresponding rotation of the pedicle screw 10, thereby allowing thepedicle screw 10 to be inserted and removed from a target location. Theinteraction of coupling 30 and recess 20 in screw 10 permits the screwto be driven in response to a driver tool which engages the coupling,even if the screw is disposed at an angle relative to the coupling.Thus, the screw shaft and driving tool can be out of alignment duringinsertion of the screw into bone.

The coupling 30 and the pedicle screw 10 are inserted into the housing70. The distal opening in the housing 70 has a greater diameter than theouter diameters of either the head 18 or the coupling 30. The insert 50is slid over the shank 16 of the pedicle screw 10 and threaded into thebottom of the housing 70. The opening 54 of the insert 50 has a diameterthat is less than that of the head 18 of the pedicle screw 10, therebyinhibiting the pedicle screw 10 from passing through the opening 54 ofthe insert 50. By threading the insert 50 into the bottom of the housing70, the pedicle screw 10 and the coupling 30 are retained in the housingand form the assembled polyaxial screw assembly 100. The pedicle screw10 is rotatable and pivotable in relation to the housing 70.

After the polyaxial screw assembly 100 is positioned at a desiredlocation in a patient, a rod member (not shown) is placed in the saddle76 and is retained in the housing 70 using a locking screw (not shown).As the locking screw is tightened against the rod member, the rod memberpresses against the coupling 30, thereby pressing the head 18 of thepedicle screw 10 against the inner surfaces of the insert 50 andsecuring the pedicle screw 10 in position (i.e. locks the screw inplace).

Polyaxial screw assembly 100 may be composed of a range of biocompatiblematerials including, but not limited to, titanium, titanium alloys,stainless steel, cobalt chrome and cobalt chrome alloys, ultra highmolecular weight polyethylene, PEEK (polyetheretherketone), and otherpolymers such as polycarbonate urethane. A variety of manufacturingtechniques may be employed to produce polyaxial screw assembly 100.

In another embodiment, shown in FIG. 6, polyaxial screw assembly 200includes a pedical screw 110, a coupling 130, an insert 50, and ahousing 70. The insert 50 and the housing 70 are similar to those ofpolyaxial screw assembly 100. Pedicle screw 110 is similar to pediclescrew 10, except that pedicle screw 110 has six gaps 117 placed an equaldistance about a recess 120. Coupling 130 is similar to coupling 30,except that coupling 130 has six knobs 136 placed an equal distanceabout the tapered outer surface 133. The six knobs 136 of the coupling130 align with the six slots 117 of the pedicle screw 110. The taperedouter surface 133 and recess 120 slidably interface. It is envisionedthat other numbers of knobs and slots may be utilized.

In still another embodiment, shown in FIGS. 7 and 8, polyaxial screwassembly 300 includes a pedicle screw 210, a coupling 230, an insert 50,a housing 70, and three connectors 280. The insert 50 and the housing 70are similar to those of polyaxial screw assembly 100. Pedicle screw 210is similar to pedicle screw 10, except that pedicle screw 210 does nothave gaps 17. Pedicle screw 210 has three slots 217 placed an equaldistance about a recess 220. Coupling 230 is similar to coupling 30,except that coupling 230 does not have knobs 36. Coupling 230 has threeslots 236 placed an equal distance about the tapered outer surface 233.The slots 236 of the coupling 230 match with slots 217 of the pediclescrew. As shown in FIG. 8, three generally spherical load transferringconnectors 280 are sized to fit into slots 217 and slots 236. Thetapered outer surface 233 and recess 220 are allowed to slidablyinterface.

It will be understood that various modifications may be made to theembodiments of the presently disclosed polyaxial screw assembly. By wayof example only, the insert could be welded to the housing instead of orin addition to engaging the housing by a threaded engagement. Therefore,the above description should not be construed as limiting, but merely asexemplifications of embodiments. Those skilled in the art will envisionother modifications within the scope and spirit of the presentdisclosure.

1. A polyaxial screw assembly comprising: a screw having a shank and ahead; a coupling engageable with the head of the screw; an insert havingthreads on an exterior surface thereof and an opening extendingtherethrough; and a housing having a passage therethrough for receivingthe screw, the passage being partially threaded for engaging the threadson the insert.
 2. The polyaxial screw assembly of claim 1, wherein thehousing is configured to releasably receive an orthopedic rod.
 3. Thepolyaxial screw assembly according to claim 2, wherein the housing formsa u-shaped saddle about a proximal section thereof.
 4. The polyaxialscrew assembly according to claim 1, wherein the insert, the screw, thecoupling and the housing are formed of a biocompatible material.
 5. Thepolyaxial screw assembly according to claim 1, wherein the opening ofthe insert has a diameter that is larger than the shank of the screw andsmaller than the head of the screw.
 6. The polyaxial screw assemblyaccording to claim 1, wherein the screw includes a cutting portion. 7.The polyaxial screw assembly according to claim 1, wherein the housinghas threads formed about an inner surface thereof toward a proximal endof the passageway.
 8. The polyaxial screw assembly according to claim 1,wherein the shank of the screw is movable relative to a longitudinalaxis of the housing.
 9. The polyaxial screw assembly according to claim8, wherein the coupling engages the head of the screw such that thescrew is pivotable relative to the longitudinal axis at a predeterminedangle.
 10. The polyaxial screw assembly according to claim 1, whereinthe coupling has a series of radial protrusions and the screw head has aseries of radially located recesses configured to accept the series ofradial protrusions.
 11. The polyaxial screw assembly according to claim1, wherein the screw head has a concave recess and the coupling has acomplimentary lower surface configured to allow pivotal motion of thescrew with respect to the coupling.
 12. The polyaxial screw assemblyaccording to claim 11, wherein the complimentary lower surface of thecoupling has a series of radially located grooves.
 13. The polyaxialscrew assembly according to claim 12, further comprising a series ofload transferring connectors, at least one of the series of loadtransferring connectors is located within each of the series of radiallylocated grooves of the coupling.
 14. The polyaxial screw assemblyaccording to claim 10, wherein a rotational force applied to saidcoupling is translated through the series of radial protrusions andbears against the series of radially located recesses, such that therotational force acting upon the coupling causes a rotational movementof the screw.
 15. A polyaxial screw assembly, comprising: a screw havinga shank and a head, the head of the screw including a plurality ofradially located recesses defined therein; a coupling including aplurality of radial protrusions configured to engage the recesses of thescrew head; an insert having threads on an exterior surface thereof andan opening extending therethrough; and a housing having a passagetherethrough for receiving the screw head and the coupling, the passagebeing partially threaded for engaging the threads on the insert.
 16. Apolyaxial screw assembly, comprising: a screw having a shank and a head;a coupling engageable with the head of the screw by one or more loadtransferring connectors; an insert having threads on an exterior surfacethereof and an opening extending therethrough; and a housing having apassage therethrough for receiving the screw, the passage beingpartially threaded for engaging the threads on the insert.
 17. Apolyaxial screw assembly comprising: a screw having a shank and a head,the head having a concave recess and a plurality of radially locatedrecesses; a coupling having a convex portion configured to be receivedwithin the concave recess of the screw head, and a plurality of radialprotrusions, each radial protrusion configured and dimensioned to bereceived in a corresponding radially located screw head recess; ahousing having a passage therethrough for receiving the screw head andthe coupling; and an insert having an opening therethrough to receivethe screw shank, the insert being engageable with the housing to retainthe screw head and the coupling in the housing.
 18. The polyaxial screwassembly according to claim 17, wherein rotational force applied to thecoupling is translated through the plurality of radial protrusions tothe radially located recesses to cause rotation of the screw.
 19. Thepolyaxial screw assembly according to claim 18, wherein the coupling andthe screw are disposed at an angle to each other as the rotational forceis applied.
 20. The polyaxial screw assembly according to claim 17wherein the housing passage includes a threaded portion and the inserthas threads on an exterior surface thereof, the threads of the insertengageable with the threads of the housing passage to retain the screwhead and the coupling in the housing.